Methods and apparatus related to a purge valve for a capacitor

ABSTRACT

In some embodiments, an apparatus includes a housing and a purge valve. The housing defines a cavity and a lumen extending from a volume of the cavity to a volume outside the cavity. The purge valve is disposed within the lumen and includes an occlusion member. A portion of the occlusion member has a width substantially equal to a width of an end portion of the lumen such that the portion of the occlusion member is disposed within the end portion of the lumen when the purge valve is in a first configuration. The portion of the occlusion member being disposed outside the end portion of the lumen when the purge valve is in a second configuration.

BACKGROUND

Embodiments described herein relate generally to purge values, and, inparticular, to purge valves for use in capacitors.

During operation, pressure buildup can occur within a housing of knownenergy storage devices, such as electrochemical double layer capacitors(EDLCs) and pseudocapacitors. Such pressure can result from, forexample, ripple voltage or over voltage. Some known EDLCs andpseudocapacitors are fitted with a burst disk that opens and/or burstswhen excessive pressure develops within the housing. For example, someknown burst disks open when a pressure within the housing exceeds 100psi. Known EDLCs and pseudocapacitors include burst disks as a safetymeasure to prevent the housing from rupturing due to excessive pressure.

Once a burst disk opens and/or bursts, exposure to the surroundingatmosphere can cause the EDLC or pseudocapacitor to rapidly deteriorate.Such deterioration reduces the effectiveness and the life of the energystorage device. As such, once the burst disk is opened, the EDLC orpseudocapacitor should be replaced as soon as possible.

Thus, a need exists for methods and apparatus related to a purge valvethat releases pressure within a housing of an energy storage device whenexcessive pressure develops within the housing but prevents and/orminimizes the deterioration of the energy storage device due to exposureto the surrounding atmosphere.

SUMMARY OF THE INVENTION

In some embodiments, an apparatus includes a housing and a purge valve.The housing defines a cavity and a lumen extending from a volume of thecavity to a volume outside the cavity. The purge valve is disposedwithin the lumen and includes an occlusion member. A portion of theocclusion member has a width substantially equal to a width of an endportion of the lumen such that the portion of the occlusion member isdisposed within the end portion of the lumen when the purge valve is ina first configuration. The portion of the occlusion member beingdisposed outside the end portion of the lumen when the purge valve is ina second configuration.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 are schematic illustrations of a capacitor housing havinga purge valve in a first position and a second position, respectively,according to an embodiment.

FIG. 3 is an exploded view of a capacitor housing and a purge valve,according to another embodiment.

FIG. 4 is a front view of the purge valve shown in FIG. 3.

FIG. 5 is a front view of the purge valve shown in FIG. 3 with thecapacitor housing shown transparent.

FIG. 6 is a top view of a lumen of the capacitor housing shown in FIG.3.

FIG. 7 is a side perspective view of the purge valve shown in FIG. 3.

FIG. 8 is a flow chart illustrating a method of releasing pressurewithin a housing of an energy storage device, according to anotherembodiment.

DETAILED DESCRIPTION

In some embodiments, an apparatus includes a housing and a purge valve.The housing defines a cavity and a lumen extending from a volume of thecavity to a volume outside the cavity. The purge valve is disposedwithin the lumen and includes an occlusion member. A portion of theocclusion member has a width substantially equal to a width of an endportion of the lumen such that the portion of the occlusion member isdisposed within the end portion of the lumen when the purge valve is ina first configuration. The portion of the occlusion member beingdisposed outside the end portion of the lumen when the purge valve is ina second configuration.

In some embodiments, the purge valve can move between its firstconfiguration and its second configuration as needed. For example, theocclusion member can pneumatically isolate the volume of the cavity fromthe volume outside the cavity when the purge valve is in the firstconfiguration such that pressure can develop, accumulate and/or build-upwithin the cavity. When a pressure within the cavity is greater than apredetermined pressure threshold, the purge valve can move from itsfirst configuration to its second configuration to release the pressure.Similarly, when the pressure within the cavity is reduced to be lessthan the predetermined pressure threshold, the purge valve can move fromits second configuration to its first configuration to once againpneumatically isolate the volume of the cavity from the volume outsidethe cavity.

In some embodiments, an apparatus includes an occlusion member, at leastone biased member, and an adjustable member. The occlusion member isdisposed within a lumen of a housing and is configured to pneumaticallyisolate a volume defined by the housing with a volume outside thehousing when in a first position. The occlusion member is substantiallyaligned along a longitudinal axis defined by the lumen of the housing.The at least one biased member is disposed adjacent to the occlusionmember and is configured to bias the occlusion member in its firstposition. The at least one biased member defines a lumen substantiallyaligned along the longitudinal axis. The adjustable member is configuredto retain the occlusion member and the at least one biased member withinthe lumen of the housing. The adjustable member defines a lumensubstantially aligned along the longitudinal axis. The volume defined bythe housing is in pneumatic communication with the volume outside thehousing via the lumen of the at least one biased member and the lumen ofthe adjustable member when the occlusion member is in a second position.

In some embodiments, an apparatus includes a housing defining a cavityand a lumen, at least one capacitor disposed within the cavity of thehousing, and a purge valve having a threaded portion. The purge valve isdisposed within the lumen when in a first configuration. The purge valveis configured to pneumatically isolate a volume defined by the cavityfrom a volume outside the housing when the purge valve is in the firstconfiguration and a pressure within the cavity is less than apredetermined pressure. The volume defined by the cavity is in pneumaticcommunication with the volume outside the housing when the purge valveis in a second configuration. The purge valve can be moved from itsfirst configuration to its second configuration by unscrewing thethreaded portion from the housing.

FIGS. 1 and 2 are schematic illustrations of a capacitor housing 110having a purge valve 150 in a first position and a second position,respectively, according to an embodiment. The capacitor housing 110 canbe any suitable housing in which at least one capacitor can be disposed,as further described in detail herein. In some embodiments, for example,the housing can be constructed of a metal (e.g., aluminum), plastics,polymers, resins, or combinations thereof, such as, for example,polycarbonate, polyethylene, or polypropylene. In some embodiments, thecapacitor housing 110 can be constructed similar to the cases shown anddescribed in co-pending U.S. patent application Ser. No. 12/424,830,filed Apr. 16, 2009, and entitled “Prismatic Polymer Case forElectrochemical Devices,” the disclosure of which is incorporated hereinby reference in its entirety.

The capacitor housing 110 defines a cavity 115 and a lumen 120. Thecavity 115 is configured to contain and/or store at least one capacitor.In some embodiments, for example, multiple electrochemical double layercapacitors (EDLCs) and/or multiple pseudocapacitors can be disposedwithin the cavity 115. More specifically, multiple electrodes and/orelectrolyte can be stored within the cavity 115. Such EDLCs and/orpseudocapacitors can be electrically coupled in series to increase theoutput voltage and/or in parallel to reduce the effective seriesresistance (ESR) and increase the power density of the device. In someembodiments, the capacitors can be similar to the capacitors shown anddescribed in co-pending U.S. patent application Ser. No. 12/229,922,filed Aug. 28, 2008, and entitled “High Voltage EDLC Cell and Method forthe Manufacture Thereof,” the disclosure of which is incorporated hereinby reference in its entirety. In some embodiments, the housing can alsoinclude an anode and a cathode (not shown in FIG. 1 or 2) electricallycoupled to the electrodes of the capacitors within the capacitor housing110 to provide power to a load and/or a device.

The lumen 120 extends from the cavity 115 to a volume outside thecapacitor housing 110. Similarly stated, the lumen 120 pneumaticallycouples the cavity 115 with a volume surrounding the capacitor housing110 and/or a volume outside the capacitor housing. As such, the pressurewithin the cavity 115 can be equalized with the pressure outside thecapacitor housing 110 via the lumen 120. More specifically, through thelumen 120, the pressure within the cavity 115 can be equalized withatmospheric pressure.

The lumen 120 includes a first end portion 122 and a second end portion124. As shown in FIGS. 1 and 2, the first end portion 122 has a widthgreater than the second end portion 124. As discussed in further detailherein, this allows the purge valve 150 to fit within the lumen 120.

In some embodiments, a semi-permeable material can be disposed in thelumen 120 or positioned in the capacitor housing 110 covering the secondend portion 124 of the lumen 120. The semi-permeable material can allowcertain gases produced in the capacitor housing 110 during periods ofrapid charging or overcharging to pass through while being hydrophobicand substantially impermeable to liquid electrolyte so that thecapacitor will not leak via the purge valve 150. The semi-permeablematerial can be formulated to resist chemical degradation from contactwith the electrolyte.

The semi-permeable material can be configured to allow certain gases(e.g., hydrogen and oxygen) to pass therethrough, while preventingliquids and/or higher molecular weight or toxic gases from escaping thecapacitor. For example, the semi-permeable material can be made from amicroporous polytetrafluorethylene sheet or sheets with a porosity thatallows certain gases to pass therethrough, while preventing liquidsand/or other gases from escaping through the purge valve 150. In someembodiments, the semi-permeable material can be made from apolytetrafluorethylene sheet having an average pore size in the range offrom about 2 to about 10 microns (preferably from about 5 to about 10microns), and a thickness in the range of 0.005 to 0.030 inches. Such asemi-permeable material has been found to permit relatively rapidventing of oxygen and hydrogen gas, and to be highly resistant to attackby electrolytes. Additionally, and depending upon pore size, it issubstantially impermeable or only slightly permeable to electrolytesnormally employed in EDLCs.

The purge valve 150 can be any suitable structure configured to fitwithin the lumen 120. As shown in FIGS. 1 and 2, the purge valve 150includes a first end portion 152 and a second end portion 154. In someembodiments, the first end portion 152 can have a width substantiallyequal to the first end portion 122 of the lumen 120 and the second endportion 154 can have a width substantially equal to the second endportion 124 of the lumen 120. This allows the purge valve 150 to fitwithin the lumen 120. For example, as shown in FIG. 1, the first endportion 152 of the purge valve 150 can be complementary to the first endportion 122 of the lumen 120. Similarly, the second end portion 154 ofthe purge valve 150 can be complementary to the second end portion 124of the lumen 120. Similarly stated, the purge valve 150 can fit snuglyand/or tightly within the lumen 120. As such, when the purge valve 150is positioned within the lumen 120 in its first position (FIG. 1), thecavity 115 is pneumatically isolated from the volume surrounding and/oroutside the capacitor housing 110. Said another way, the cavity 115 ispneumatically isolated from atmospheric pressure when the purge valve150 is in its first position.

The purge valve 150 has a first position (FIG. 1) and a second position(FIG. 2). As discussed above, when the purge valve 150 is in its firstposition (FIG. 1), the purge valve 150 fits snugly and/or tightly withinthe lumen 120. Additionally, when the purge valve is in its firstposition, the cavity 115 is pneumatically isolated from the volumesurrounding and/or outside the capacitor housing 110 (e.g.,pneumatically isolated from atmospheric pressure). Accordingly, pressurewithin the cavity can accumulate, build-up and/or develop. Additionally,the electrodes and/or electrolyte that define the capacitors within thecavity 115 are pneumatically isolated from the volume surrounding and/oroutside the capacitor housing 110 when the purge valve 150 is in itsfirst position. Thus, the capacitors are not exposed to the surroundingatmosphere.

The purge valve 150 is biased in its first position (FIG. 1). Similarlystated, during normal operation, the purge valve 150 is in its firstposition. Accordingly, during normal operation, the electrodes and/orelectrolyte disposed within the cavity 115 are pneumatically isolatedfrom the volume surrounding the housing 110. This prevents theelectrodes and electrolyte from deteriorating during normal operation.

When the purge valve 150 is in its second position (FIG. 2), the purgevalve 150 is not completely disposed within the lumen 120. As such, anair passage and/or a pneumatic path is defined through the lumen 120between the cavity 115 and the volume surrounding the housing 110.Similarly stated, the cavity is in pneumatic communication with thevolume surrounding and/or outside the housing 110. Accordingly, pressurewithin the cavity can be equalized with the pressure surrounding and/oroutside the housing 110 (e.g., atmospheric pressure) when the purgevalve 150 is in its second position. This can reduce and/or releasepressure built-up within the cavity 115.

The purge valve 150 moves from its first position (FIG. 1) to its secondposition (FIG. 2) when a pressure within the cavity 115 exceeds a firstpredetermined pressure threshold. More particularly, when the pressurewithin the cavity 115 exceeds the first predetermined pressurethreshold, the pressure can cause the purge valve to move in thedirection shown by the arrow AA in FIG. 1. Similarly stated, thepressure within the cavity 115 can exert a force on the purge valve 150in the direction shown by the arrow AA in FIG. 1. This force causes thepurge valve to move into its second position (FIG. 2). In someembodiments, such a first predetermined pressure threshold can bebetween 103-110 pounds per square inch (psi). In other embodiments, thefirst predetermined pressure threshold can be less than 103 psi. Instill other embodiments, the first predetermined pressure threshold canbe greater than 110 psi.

While the purge valve 150 is in its second position (FIG. 2), thepressure within the cavity 115 can be reduced and/or released via theair passage and/or pneumatic path. More specifically, the pressurewithin the cavity 115 can be released into the volume surrounding and/oroutside the capacitor housing 110. Similarly stated, the pneumaticcommunication between the cavity 115 and the surrounding atmosphere canreduce the pressure within the cavity 115.

After the pressure within the cavity 115 falls below a secondpredetermined pressure threshold, the purge valve 150 can move from itssecond position (FIG. 2) to its first position (FIG. 1). Morespecifically, after the pressure within the cavity 115 falls below thesecond predetermined threshold, the force exerted by the pressure withinthe cavity 115 on the purge valve 150 in the direction shown by thearrow AA in FIG. 1 is no longer large enough to retain the purge valve150 in its second position. Accordingly, the purge valve 150 moves inthe direction shown by the arrow BB in FIG. 2 to its first configuration(FIG. 1). Accordingly, the air passage and/or pneumatic path between thecavity 115 and the surrounding atmosphere is sealed and/or closed andthe cavity is pneumatically isolated from the surrounding atmosphere.

In some embodiments, the second predetermined pressure threshold can besubstantially equal to the first predetermined pressure threshold. Insuch embodiments, the purge valve 150 moves from the first position tothe second position and the second position to the first position atsubstantially the same predetermined pressure threshold. In otherembodiments, the second predetermined pressure threshold is less thanthe first predetermined pressure threshold. This allows the pressurewithin the cavity 115 to fall a predetermined amount of pressure belowthe first predetermined pressure threshold before the purge valve 150 ismoved from its second position to its first position. This helps toensure that the purge valve 150 is not frequently moving between itsfirst position and its second position. Similarly stated, in suchembodiments, after the purge valve 150 is moved from its second positionto its first position, the pressure within the cavity can increase anamount before the purge valve 150 again moves from the first position tothe second position. Such embodiments can be said to include ahysteretic effect.

Such a resealable purge valve 150 can be used to release the pressurewithin the cavity 115 without exposing the contents of the cavity (e.g.,the electrodes and the electrolyte of the capacitors) to the surroundingatmosphere for prolonged periods of time. Accordingly, the capacitorswithin the housing 110 can be operational and/or used for longer periodsof time after the purge valve 150 releases the pressure within thecavity 115 than capacitors within housings without a resealable purgevalve. Specifically, the capacitors within a housing 110 having aresealable purge valve 150 can be exposed to the surrounding atmosphereless than capacitors within a housing without a resealable purge valve.Accordingly, less degradation occurs in capacitors within a housing 110having a resealable purge valve 150.

Additionally, such a resealable purge valve 150 allows the pressurewithin the cavity 115 to be released more than once. For example, ifafter the purge valve 150 is moved from its second position (FIG. 2) toits first position (FIG. 1) the pressure within the cavity 115 exceedsthe first predetermined pressure threshold, the purge valve 150 can onceagain move from its first position to its second position to release thepressure within the cavity 150. This cycle can occur any number oftimes. This extends the life and use of the capacitors disposed withinthe housing 110.

FIGS. 3-7 illustrate a resealable purge valve 200, according to anotherembodiment. Specifically, FIG. 3 is an exploded view of a capacitorhousing 280 and a purge valve 200, according to another embodiment. Thecapacitor housing 280 can be any suitable capacitor housing defining acavity (not shown) and a lumen 282. As such, the capacitor housing canbe similar to the capacitor housing 110.

Similar to the cavity 115 defined by capacitor housing 110, the cavity(not shown) defined by the capacitor housing 280 can include one or morecapacitors. In some embodiments, for example, multiple electrochemicaldouble layer capacitors (EDLCs) and/or multiple pseudocapacitors can bedisposed within the cavity. More specifically, electrolyte and/ormultiple electrodes can be stored within the cavity. Such EDLCs and/orpseudocapacitors can be electrically coupled in series to increase theoutput voltage and/or in parallel to reduce the effective seriesresistance (ESR) and increase the power density of the device. In someembodiments, the housing can also include an anode and a cathode (notshown) electrically coupled to the electrodes of the capacitors withinthe capacitor housing 280 to provide power to a load and/or a device.

Similar to the lumen 120, the lumen 282 can pneumatically couple thecavity within the housing 280 with a volume surrounding the housing 282.Similarly stated, the cavity can be in pneumatic communication with asurrounding atmosphere via the lumen 282. Accordingly, a pressure withinthe cavity can be equalized with atmospheric pressure via the lumen 282.Similarly stated, a pressure within the cavity can be reduced and/orreleased via the lumen 282.

FIGS. 5 and 6 illustrate the lumen 282 in greater detail. The lumen 282includes a first end portion 284, a second end portion 286 and a taperedportion 288. As shown in FIG. 6, the first end portion 284 has a firstwidth W1 and the second end portion 286 has a second width W2, less thanthe first width W1. As shown in FIG. 5 and as described in furtherdetail herein, the first end portion 284 is configured to receive anadjustable member 210 of the purge valve 200. As such, the adjustablemember 210 is configured to be releasably coupled to the first endportion 284 of the lumen 282. In some embodiments, for example, asidewall of the first end portion of the lumen includes a threadedportion configured to matingly receive a threaded portion of theadjustable member 210, as further described herein. In otherembodiments, the first end portion 284 of the lumen can include anyother type of connector to matingly receive the adjustable member 210.

As shown and described in FIG. 5 and as described in further detailherein, the second end portion 286 of the lumen 282 is configured toreceive an occlusion member 240 of the purge valve 200. As described infurther detail herein, the occlusion member 240 is configured to bedisposed within the second end portion 286 of the lumen 282 when in afirst position. When in the first position, the occlusion member 240defines a pneumatic seal with the second end portion 286. Similarlystated, the occlusion member 240 pneumatically isolates the lumen 282from the cavity (not shown) when disposed within the second end portion286 of the lumen 282.

The tapered portion 288 of the lumen 282 is disposed between the firstend portion 284 of the lumen 282 and the second end portion 286 of thelumen. The tapered portion 288 is effective to properly reseat theocclusion member 240 in the second end portion 286 of the lumen 282 whenthe occlusion member 240 is moved from its second position to its firstposition, as described in further detail herein. Similarly stated, thetapered portion 288 can facilitate/help guide and/or direct theocclusion member 240 into its first position.

The purge valve 200 includes an occlusion member 240, a biased member230, a washer 220 and an adjustable member 210. The occlusion member 240can be any suitable structure configured to fit within the second endportion 286 of the lumen 282 when in a first position but define apneumatic passage through the lumen when in a second position, asdescribed in further detail herein. Similarly stated, the occlusionmember 240 can be any suitable structure that occludes and/orpneumatically seals the second end portion 286 of the lumen when in thefirst position but does not occlude and/or pneumatically seal the secondend portion 286 of the lumen when in the second position. As shown inFIGS. 3-5 and 7, the occlusion member 240 can be a sphere having adiameter greater than the width W2 of the second end portion 286 of thelumen 282. In such embodiments, a portion of the sphere extends into thesecond end portion 286 of the lumen 282 (FIG. 5). In other embodiments,the occlusion member 240 can be any other shape and/or structure, suchas a rectangular prism, an ovoid, a pyramid, and/or the like.

The biased member 230 can be any structure configured to bias theocclusion member 240 in its first position. Similarly stated, the biasedmember 230 can be any structure configured to retain the occlusionmember 240 within the second end portion 286 of the lumen 282 when apressure within the cavity of the housing 280 is below a pressurethreshold. As shown in FIGS. 3, 5 and 7, the biased member 230 can be awave washer. As shown in FIG. 7, such a wave washer can define a lumen232 configured to receive a portion of the occlusion member 240. In suchembodiments, the lumen 232 can have a width smaller than a width of theocclusion member 240. As such, a portion of the occlusion member 240 canbe received by the lumen 232 when a pressure within the cavity isgreater than a pressure threshold, as described in further detailherein. Additionally, in such embodiments, because of the wave structureof the biased member 230, a first portion of an inner surface of thebiased member 230 contacts the occlusion member 240 while a secondportion of the inner surface of the biased member 230 does not contactthe occlusion member 240. The lumen 232 can facilitate the retention ofthe occlusion member 240 in substantial alignment with the second endportion 286 of the lumen 282 when the occlusion member 240 is in thesecond position.

In other embodiments, the biased member can be any other suitablestructure. Accordingly, the biased member 230 can exert a force on theocclusion member 240 such that the occlusion member is biased in itsfirst position. In some embodiments, for example, the biased member canbe one or more springs, a flexible lock washer, and/or the like.

In some embodiments, the biased member 230 has a first position and asecond position, corresponding to the first position and the secondposition of the occlusion member 240. Accordingly, when the occlusionmember 240 is moved from its first position to its second position, theocclusion member 240 moves the biased member 230 from its first positionto its second position. Similarly, when the biased member 230 moves fromits second position to its first position, the biased member 230 movesthe occlusion member 240 from its second position to its first position.

The washer 220 can be any suitable washer to be disposed between thebiased member 230 and the adjustable member 210. In some embodiments,and as shown in FIG. 7, the washer defines a lumen 222. The lumen of thewasher 220 is aligned with the lumen of the biased member 230, asdescribed in further detail herein. In other embodiments, the purgevalve does not include a washer. In such embodiments, the biased membercan directly contact the adjustable member.

The adjustable member 210 can be any suitable member disposed within thelumen 282. The adjustable member 210 is coupled to the first end portion284 of the lumen 282. More specifically, the adjustable member 210 iscoupled to the lumen 282 such that an end portion of the adjustablemember 210 is disposed within the lumen 282 a distance. Accordingly, theadjustable member 210 retains the washer 220, the biased member 230 andthe occlusion member 240 within the lumen 282 when the adjustable member210 is coupled to the first end portion 284 of the lumen 282.

As discussed above, the adjustable member 210 can be removably coupledto the first end portion 284 of the lumen 282 using any suitablecoupling portion and/or mechanism. In some embodiments, for example, theadjustable member 210 includes a threaded portion configured to matinglyengage a threaded portion of the lumen 280. In other embodiments, anyother suitable coupling mechanism can be used to removably couple theadjustable member 210 to the first end portion 284 of the lumen 282.

The adjustable member 210 defines a lumen 212. In some embodiments, thelumen 212 is configured to pneumatically couple the cavity of thehousing 280 with the volume surrounding the housing 280 when theocclusion member 240 is in its second position. Accordingly, when theocclusion member 240 is in its second position, the lumen 212 of theadjustable member 210 is part of an air passage and/or a pneumatic pathdefined between the cavity of the housing 280 and the volume surroundingand/or outside the housing 280, as described in further detail herein.

The lumen 282 of the housing 280 defines a longitudinal axis A_(L)(FIGS. 5 and 7). As shown in FIGS. 5 and 7, the adjustable member 210,the washer 220, the biased member 230 and the occlusion member 240 aresubstantially aligned along the longitudinal axis A_(L) within the lumen282. More specifically, the lumen 212 of the adjustable member 210, thelumen 222 of the washer 220, the lumen 232 of the biased member, and acenter portion of the occlusion member 240 are substantially alignedalong the longitudinal axis A_(L).

In use, the purge valve 200 is assembled by placing the occlusion member240, the biased member 230, the washer 220 and the adjustable member 210into the lumen 282 defined by the housing 280, as shown in FIG. 5.Specifically, the occlusion member 240 can be disposed within the lumen282 such that the occlusion member 240 is partially disposed within thesecond end portion 286 of the lumen 282. The biased member 230 can thenbe placed in the lumen 282 such that the biased member contacts and/orabuts the occlusion member 240. The washer 220 can be placed on top ofand/or contacting the biased member 230 and the adjustable member 210can be releasably coupled to the first end portion 284 of the lumen 282.In some embodiments, for example, the adjustable member 210 can bescrewed into the lumen until the occlusion member 240 is tightlydisposed within the second end portion 286 of the lumen 282. Asdescribed in further detail herein, in some embodiments, thepredetermined pressure within the cavity at which the occlusion member240 moves from its first position to its second position can be adjustedby the distance the adjustable member 210 extends within the lumen 282of the housing 280.

After the purge valve 200 is disposed and/or assembled within the lumen282, electrodes and/or electrolyte can be placed and/or inserted withinthe cavity (not shown) of the housing 280. In other embodiments, theelectrodes and/or electrolyte can be placed and/or inserted within thecavity of the housing 280 prior to placing and/or assembling the purgevalve 200 within the lumen 282. After the purge valve 200 is disposedand/or assembled within the lumen 282 and the electrodes and/orelectrolyte are placed within the cavity of the housing 280 (e.g., toassemble one or more capacitors), an anode and a cathode electricallycoupled to the electrodes can be coupled to a load and the energystorage device can begin to operate and/or function (e.g., by providingpower to the load).

During normal operation, the purge valve 200 remains in its firstposition. Similarly stated, the biased member 230 exerts a force on theocclusion member 240 in the direction shown by the arrow DD in FIGS. 5and 7 such that the occlusion member 240 is retained within the secondend portion 286 of the lumen 282 (e.g., FIG. 5). Accordingly, the cavityof the housing 280 (and thus the electrodes and the electrolyte) arepneumatically isolated from the volume surrounding the housing 280.Thus, pressure can build-up, accumulate and/or increase within thecavity.

If the pressure within the cavity of the housing 280 rises and/orincreases above a first predetermined pressure threshold, the pressurewithin the cavity exerts a force on the occlusion member 240 in thedirection shown by the arrow CC in FIGS. 5 and 7 greater than the forceexerted on the occlusion member 240 by the biased member 230 in thedirection shown by the arrow DD in FIGS. 5 and 7. Accordingly, the forceexerted on the occlusion member 240 by the pressure in the cavity causesthe occlusion member 240 to move in the direction shown by the arrow CC.This movement breaks the pneumatic seal between the occlusion member 240and the second end portion 286 of the lumen 282. Similarly stated, thismovement causes an air passage and/or a pneumatic path to be definedfrom the cavity to the volume surrounding and/or outside the housing280. More specifically, the lumen 212 of the adjustable member 210, thelumen 222 of the washer 220, the lumen of the biased member 230 and thesecond end portion 286 of the lumen 282 define an air passage and/or apneumatic path between the cavity and the volume surrounding and/oroutside the housing 280. Via the air passage and/or the pneumatic path,the pressure within the cavity of the housing 280 can be reduced and/orreleased.

While in its second position, the occlusion member 240 can remainaligned with the second end portion 286 of the lumen 282 along thelongitudinal axis A_(L) because of the lumen 232 of the biased member230. More specifically, when the occlusion member 240 is moved into itssecond position, a portion of the occlusion member 240 is received bythe lumen 232 of the biased member 230. Because the lumen 232 of thebiased member 230 is substantially aligned with the second end portion286 of the lumen 282, this helps to ensure that the occlusion member 240remains substantially aligned with the second end portion 286 of thelumen 282 when in its second position.

After the pressure within the cavity of the housing 280 is reduced belowa second predetermined pressure threshold, the force exerted by thepressure within the cavity on the occlusion member 240 in the directionshown by the arrow CC is less than the force exerted on the occlusionmember 240 by the biased member 230 in the direction shown by the arrowDD. Accordingly, the force exerted on the occlusion member 240 by thebiased member 230 causes the occlusion member 240 to move from itssecond position to its first position. Similarly stated, the pneumaticseal between the occlusion member 240 and the second end portion 286 ofthe lumen 282 can be reformed. Thus, the electrodes and the electrolytedisposed within the cavity of the housing 280 are once againpneumatically isolated.

In some embodiments, the tapered portion 288 assists the biased member230 in moving the occlusion member 240 from its second position to itsfirst position. More specifically, the tapered portion 288 helps directand/or guide the occlusion member 240 into the second end portion 286 ofthe lumen 282. For example, if the occlusion member 240, when in itssecond position, is not exactly aligned with the second end portion 286of the lumen 282, when the biased member 230 moves the occlusion member240 in the direction of the second end portion 286 of the lumen 282(e.g., the direction shown by the arrow DD), the occlusion member 240can slide along the tapered portion 288 and into the second end portion286 of the lumen 282. Accordingly, the tapered portion 288 assists theocclusion member 240 in redefining the pneumatic seal with the secondend portion 286 of the lumen 282.

In some embodiments, the second predetermined pressure threshold can besubstantially equal to the first predetermined pressure threshold. Insuch embodiments, the occlusion member 240 moves from its first positionto its second position and from its second position to its firstposition at the same predetermined pressure threshold. In otherembodiments, the second predetermined pressure threshold is less thanthe first predetermined pressure threshold. This allows the pressurewithin the cavity to fall a predetermined amount of pressure below thefirst predetermined pressure threshold before the purge valve 200 ismoved from its second position to its first position. Such embodimentscan be said to have a hysteretic effect. In such embodiments, the amountof force it takes to move the occlusion member 240 (in the directionshown by the arrow CC or the direction shown by the arrow DD) is greaterthan the amount of force it takes to retain the occlusion member 240 inits current position (the first position or the second position). Assuch, the first predetermined pressure threshold (i.e., the pressurewithin the cavity needed to move the occlusion member 240 from its firstposition to its second position) is greater than the secondpredetermined threshold (i.e., the pressure within the cavity needed forthe force exerted on the occlusion member 240 by the biased member 230to move the occlusion member 240 from its second position to its firstposition). Such a hysteretic effect helps to ensure that the purge valve200 is not frequently moving between its first position and its secondposition. Similarly stated, in such embodiments, after the occlusionmember 240 is moved from its second position to its first position, thepressure within the cavity can increase an amount before the occlusionmember 240 again moves from its first position to its second position.

In some embodiments, the first predetermined threshold and/or the secondpredetermined threshold can be adjusted, calibrated and/or modified. Forexample, the amount of force applied by the biased member 230 on theocclusion member 240 (i.e., in the direction shown by the arrow DD inFIG. 7) can be adjusted, calibrated and/or modified. In someembodiments, for example, the adjustable member 210 can be tightened orloosened. More specifically, the adjustable member 210 can be moved withrespect to the housing 280 in the direction shown by the arrow CC or inthe direction shown by the arrow DD. Accordingly, the distance that anend portion of the adjustable member extends into the lumen 282 can bevaried. Such tightening or loosening can reduce or increase the amountof space between the washer 220 and the occlusion member 240,respectively.

For example, if the adjustable member 210 is tightened such that itmoves in the direction shown by the arrow DD in FIGS. 5 and 7, the spacebetween the washer 220 and the occlusion member 240 decreases. Thiscauses the biased member 230 to apply a greater force on the occlusionmember 240. Accordingly, the pressure within the cavity of the housing280 must apply a greater force on the occlusion member 240 to overcomeand/or exceed the force applied by the biased member 230 on theocclusion member 240 and move the occlusion member 240 from its firstposition to its second position. Thus, the first predetermined thresholdis increased. In some embodiments, such tightening of the adjustablemember 210 can similarly increase the second predetermined threshold.

Similarly, if the adjustable member is loosened such that it moves inthe direction shown by the arrow CC in FIGS. 5 and 7, the space betweenthe washer 220 and the occlusion member 240 increases. This causes thebiased member 230 to apply a lesser force on the occlusion member 240.Accordingly, the pressure within the cavity of the housing 280 need onlyapply a lesser force on the occlusion member 240 to overcome and/orexceed the force applied by the biased member 230 on the occlusionmember 240 and move the occlusion member 240 from its first position toits second position. Thus, the first predetermined threshold isdecreased. In some embodiments, such loosening of the adjustable member210 can similarly decrease the second predetermined threshold.

In some embodiments, additional washers 220 and/or biased members 230can be used to increase the first predetermined threshold and/or thesecond predetermined threshold. For example, by adding additionalwashers 220 between the adjustable member 210 and the biased member 230,the distance between the biased member 230 and the second end portion286 of the lumen 282 decreases. Thus, the biased member 230 is furthercompressed between the washers 220 and the second end portion 286 of thelumen 282, causing the biased member 230 to exert a greater force on theocclusion member 240 in the direction shown by the arrow DD.Accordingly, a greater pressure within the cavity of the housing 280 isneeded to overcome and/or exceed the force exerted on the occlusionmember 240 by the biased member 230. Thus, the first predeterminedthreshold is increased.

In some embodiments, adding additional washers 220 can similarlyincrease the second predetermined threshold. As discussed in more detailherein, the design specifications of the biased member 230 influencesthe pressure threshold at which the occlusion member 240 moves betweenits first and second positions. In other words, the stiffness of thebiased member can be chosen to define the desired pressure threshold.Additionally, a combination of various materials can be used to definethe pressure threshold. In other words, the stiffness of the occlusionmember 240, the washer 220 and the biased member 230 can be taken intoaccount when configuring the valve to be responsive to a predeterminedpressure threshold.

Similarly, adding additional biased members 230 between the washer 220and the occlusion member 240 increases the force exerted on theocclusion member 240 by the biased members 230. Adding additional biasedmembers 230 decreases the distance between the biased members 230 andthe second end portion 286 of the lumen 282 and increases the stiffnessof the biased members 230. Accordingly, a greater pressure within thecavity of the housing 280 is needed to overcome and/or exceed the forceexerted on the occlusion member 240 by the biased members 230. Thus, thefirst predetermined threshold is increased. In some embodiments, addingadditional biased members 230 can also increase or decrease the secondpredetermined threshold. For example, a purge valve 200 with one biasedmember can provide a first predetermined threshold of 100 psi and asecond predetermined threshold of 115 psi. By adding a second biasedmember, the first predetermined threshold is increased to 103 psi andthe second predetermined threshold is decreased to 110 psi. In otherembodiments, replacing the biased member 230 with a stiffer and/or lesselastic biased member can increase the first predetermined thresholdand/or the second predetermined threshold. Similarly, replacing thebiased member 230 with a more elastic biased member can decrease thefirst predetermined threshold and/or the second predetermined threshold.Thus, the purge valve 200 can be customized to operate at any range ofpressures simply by changing the number of washers and/or biased membersor by selecting washers and/or biased members with certain materialproperties to achieve the desired pressure range.

In some embodiments, the pressure within the cavity of the housing 280can be manually relieved. For example, a user of the device can loosenthe adjustable member 210 from the lumen 282 of the housing 280 suchthat the biased member 230 no longer retains the occlusion member 240within the second end portion 286 of the lumen 280. More specifically,the adjustable member 210 can be moved in the direction shown by thearrow CC in FIGS. 5 and 7 until the biased member 230 no longer appliesa sufficient force on the occlusion member 240 to retain the occlusionmember 240 within the second end portion 286 of the lumen 280. Thisallows the pneumatic seal between the occlusion member 240 and thesecond end portion 286 of the lumen 280 to break and an air passageand/or a pneumatic path to be defined within the second end portion 286of the lumen 280. The pressure within the cavity can be released and/orreduced via the pneumatic path. In some embodiments, the cavity can bemanually resealed (e.g., the occlusion member 240 moved to its firstposition) by tightening the adjustable member 210 such that theadjustable member 210 moves in the direction shown by the arrow DD inFIGS. 5 and 7.

FIG. 8 is a flow chart illustrating a method 300 of regulating (i.e.,maintaining and/or releasing) pressure within a housing of an energystorage device, according to another embodiment. The method 300 includesinserting a purge valve into a lumen defined by a housing such that anocclusion member of the purge valve is in a first position, at 302. Acavity defined by the housing is pneumatically isolated from the volumeoutside the cavity when the occlusion member is in the first position.Electrolyte and multiple electrodes are disposed within the cavity. Thepurge valve can be structurally and functionally similar to the purgevalve 150 and/or the purge valve 200, shown and described above.

The occlusion member is moved from its first position to a secondposition when a pressure within the cavity is greater than a firstpredetermined pressure threshold, at 304. The cavity defined by thehousing is in pneumatic communication with the volume outside the cavitywhen in its second position. Accordingly, the pressure within the cavitycan be reduced.

The occlusion member is moved from its second position to its firstposition when the pressure within the cavity is less than a secondpredetermined pressure threshold, at 306. Accordingly, the cavitydefined by the housing is once again pneumatically isolated from thevolume outside the cavity. This allows the electrolyte and the multipleelectrodes disposed within the cavity to operate without being exposedto the atmosphere surrounding the housing.

The first pressure threshold and the second pressure threshold areoptionally adjusted by adjusting an adjustable member of the purgevalve, at 308. As discussed above, such adjustments can increase and/orreduce the force applied to the occlusion member by a biased member ofthe purge valve. Increasing the force applied to the occlusion memberincreases the first pressure threshold and/or the second pressurethreshold. Decreasing the force applied to the occlusion memberdecreases the first pressure threshold and/or the second pressurethreshold.

While various embodiments have been described above, it should beunderstood that they have been presented by way of example only, and notlimitation. Where methods described above indicate certain eventsoccurring in certain order, the ordering of certain events may bemodified. Additionally, certain of the events may be performedconcurrently in a parallel process when possible, as well as performedsequentially as described above.

While various embodiments have been described above, it should beunderstood that they have been presented by way of example only, notlimitation, and various changes in form and details may be made. Anyportion of the apparatus and/or methods described herein may be combinedin any combination, except mutually exclusive combinations. Theembodiments described herein can include various combinations and/orsub-combinations of the functions, components and/or features of thedifferent embodiments described.

What is claimed is:
 1. An apparatus, comprising: a housing defining acavity and a lumen extending from a volume of the cavity to a volumeoutside the cavity, a first end portion of the lumen having a width anda second end portion of the lumen having a width less than the width ofthe first end portion, the second end portion of the lumen beingadjacent the volume of the cavity, the first end portion being adjacentthe volume outside the cavity; and a purge valve removably coupled tothe housing and disposed at least partially within the lumen, the purgevalve including an occlusion member, a portion of the occlusion memberhaving a width substantially equal to the width of the second endportion of the lumen such that the portion of the occlusion member isdisposed within the second end portion of the lumen when the purge valveis in a first configuration, the portion of the occlusion member beingdisposed outside the second end portion of the lumen when the purgevalve is in a second configuration, wherein the purge valve includes anadjustable member configured to retain the occlusion member within thelumen of the housing, the adjustable member having a plurality ofthreads configured to mate with a plurality of threads of the housing tocouple the adjustable member to the housing, the adjustable memberconfigured to be unscrewed from the housing to release a pressure withinthe cavity of the housing.
 2. The apparatus of claim 1, wherein theadjustable member defines a lumen substantially aligned with an axisdefined by the second end portion of the lumen of the housing, thevolume of the cavity being in pneumatic communication with the volumeoutside the cavity via the lumen of the adjustable member when the purgevalve is in the second configuration.
 3. The apparatus of claim 1,wherein an end portion of the adjustable member is disposed within thelumen of the housing a distance from the first end portion of the lumen,the purge valve moving from its first configuration to its secondconfiguration when a pressure within the cavity is greater than apredetermined pressure, the predetermined pressure varying as thedistance varies.
 4. The apparatus of claim 1, wherein the occlusionmember pneumatically seals the volume within the cavity from the volumeoutside the cavity when the purge valve is in the first configuration,the volume within the cavity being in pneumatic communication with thevolume outside the cavity when the purge valve is in the secondconfiguration.
 5. The apparatus of claim 1, wherein the occlusion memberis substantially spherical.
 6. The apparatus of claim 1, wherein atleast one electrochemical double layer capacitor is disposed within thecavity of the housing.
 7. The apparatus of claim 1, wherein the purgevalve includes a biased member having a first position and a secondposition, the biased member disposed adjacent the occlusion member, thebiased member being biased in its first position, the biased memberbeing in its first position and retaining the occlusion member withinthe second end portion of the lumen of the housing when the purge valveis in the first configuration, the purge valve moving from its firstconfiguration to its second configuration when a pressure within thecavity causes the occlusion member to move the biased member from itsfirst position to its second position allowing pneumatic communicationbetween the volume of the cavity and the volume outside the cavity, thebiased member returning to its first position when the pressure withinthe cavity returns below a predetermined threshold.
 8. The apparatus ofclaim 1, wherein the adjustable member defines a lumen and includes abiased member defining a lumen, the lumen of the housing defining alongitudinal axis along which the lumen defined by the adjustablemember, the lumen of the biased member and the occlusion member aresubstantially aligned.
 9. The apparatus of claim 1, wherein the purgevalve includes a biased member configured to bias the purge valve in itsfirst configuration.
 10. An apparatus, comprising: a housing defining acavity and a lumen extending from a volume of the cavity to a volumeoutside the cavity, a first end portion of the lumen having a width anda second end portion of the lumen having a width less than the width ofthe first end portion, the second end portion of the lumen beingadjacent the volume of the cavity, the first end portion being adjacentthe volume outside the cavity; and a purge valve removably coupled tothe housing and disposed at least partially within the lumen, the purgevalve including an occlusion member, a portion of the occlusion memberhaving a width substantially equal to the width of the second endportion of the lumen such that the portion of the occlusion member isdisposed within the second end portion of the lumen when the purge valveis in a first configuration, the portion of the occlusion member beingdisposed outside the second end portion of the lumen when the purgevalve is in a second configuration, wherein the purge valve includes abiased member having a first position and a second position, the biasedmember disposed adjacent the occlusion member, the biased member beingbiased in its first position, the biased member being in its firstposition and retaining the occlusion member within the second endportion of the lumen of the housing when the purge valve is in the firstconfiguration, the purge valve moving from its first configuration toits second configuration when a pressure within the cavity causes theocclusion member to move the biased member from its first position toits second position allowing pneumatic communication between the volumeof the cavity and the volume outside the cavity, the biased memberreturning to its first position when the pressure within the cavityreturns below a predetermined threshold.
 11. The apparatus of claim 10,wherein the purge valve includes an adjustable member configured toretain the occlusion member within the lumen of the housing, theadjustable member defining a lumen substantially aligned with an axisdefined by the second end portion of the lumen of the housing, thevolume of the cavity being in pneumatic communication with the volumeoutside the cavity via the lumen of the adjustable member when the purgevalve is in the second configuration.
 12. The apparatus of claim 10,wherein the purge valve includes an adjustable member configured toretain the occlusion member within the lumen of the housing, theadjustable member being removable from the housing such that manualmanipulation of the adjustable member is operative to release a pressurewithin the cavity of the housing.
 13. The apparatus of claim 10, whereinthe purge valve includes an adjustable member defining a lumen and thebiased member also defines a lumen, the lumen of the housing defining alongitudinal axis along which the lumen of the adjustable member, thelumen of the biased member, and the occlusion member are substantiallyaligned.
 14. The apparatus of claim 10, wherein the occlusion memberpneumatically seals the volume within the cavity from the volume outsidethe cavity when the purge valve is in the first configuration, thevolume within the cavity being in pneumatic communication with thevolume outside the cavity when the purge valve is in the secondconfiguration.
 15. An apparatus, comprising: a housing defining a cavityand a lumen extending from a volume of the cavity to a volume outsidethe cavity, a first end portion of the lumen having a width and a secondend portion of the lumen having a width less than the width of the firstend portion, the second end portion of the lumen being adjacent thevolume of the cavity, the first end portion being adjacent the volumeoutside the cavity; and a purge valve removably coupled to the housingand disposed at least partially within the lumen, the purge valveincluding an occlusion member, a portion of the occlusion member havinga width substantially equal to the width of the second end portion ofthe lumen such that the portion of the occlusion member is disposedwithin the second end portion of the lumen when the purge valve is in afirst configuration, the portion of the occlusion member being disposedoutside the second end portion of the lumen when the purge valve is in asecond configuration, wherein the purge valve includes an adjustablemember defining a lumen and a biased member defining a lumen, the lumenof the housing defining a longitudinal axis along which the lumen of theadjustable member, the lumen of the biased member and the occlusionmember are substantially aligned.
 16. The apparatus of claim 15, whereinthe adjustable member is configured to retain the occlusion memberwithin the lumen of the housing, the adjustable member being removablefrom the housing such that manual manipulation of the adjustable memberis operative to release a pressure within the cavity of the housing. 17.The apparatus of claim 15, wherein the volume of the cavity is inpneumatic communication with the volume outside the cavity via the lumenof the adjustable member and the lumen of the biased member when thepurge valve is in the second configuration.
 18. An apparatus,comprising: a housing defining a cavity and a lumen extending from avolume of the cavity to a volume outside the cavity, a first end portionof the lumen having a width and a second end portion of the lumen havinga width less than the width of the first end portion, the second endportion of the lumen being adjacent the volume of the cavity, the firstend portion being adjacent the volume outside the cavity; and a purgevalve removably coupled to the housing and disposed at least partiallywithin the lumen, the purge valve including an occlusion member, aportion of the occlusion member having a width substantially equal tothe width of the second end portion of the lumen such that the portionof the occlusion member is disposed within the second end portion of thelumen when the purge valve is in a first configuration, the portion ofthe occlusion member being disposed outside the second end portion ofthe lumen when the purge valve is in a second configuration, wherein thepurge valve includes a biased member configured to bias the purge valvein its first configuration.
 19. The apparatus of claim 18, wherein thepurge valve includes an adjustable member defining a lumen and thebiased member also defines a lumen, the lumen of the housing defining alongitudinal axis along which the lumen of the adjustable member, thelumen of the biased member and the occlusion member are substantiallyaligned.
 20. The apparatus of claim 18, wherein the volume of the cavityis in pneumatic communication with the volume outside the cavity via thelumen of an adjustable member and the lumen of the biased member whenthe purge valve is in the second configuration.
 21. An apparatus,comprising: an occlusion member disposed within a lumen of a housing,the occlusion member configured to pneumatically isolate a volumedefined by the housing from a volume outside the housing when in a firstposition; at least one biased member defining a lumen disposed adjacentthe occlusion member and configured to bias the occlusion member in itsfirst position; and an adjustable member defining a lumen configured toretain the occlusion member and the at least one biased member withinthe lumen of the housing, the volume defined by the housing being inpneumatic communication with the volume outside the housing via thelumen of the at least one biased member and the lumen of the adjustablemember when the occlusion member is in a second position.
 22. Theapparatus of claim 21, wherein the at least one biased member includesan inner surface defining the lumen of the at least one biased member, afirst portion of the inner surface contacting the occlusion member, asecond portion of the inner surface being disposed apart from theocclusion member.
 23. The apparatus of claim 21, wherein the occlusionmember is configured to move from its first position to its secondconfiguration when a pressure within the volume defined by the housingrises above a predetermined pressure, the at least one biased memberconfigured to move the occlusion member from its second position to itsfirst position when the pressure within the volume falls below thepredetermined pressure.
 24. The apparatus of claim 21, wherein at leastone electrochemical double layer capacitor is disposed within the volumedefined by the housing.
 25. The apparatus of claim 21, furthercomprising: a washer disposed between the at least one biased member andthe adjustable member, the washer defining a lumen substantially alignedalong the longitudinal axis.
 26. The apparatus of claim 21, wherein theadjustable member is removable from the housing such that manualmanipulation of the adjustable member is operative to release a pressurewithin the volume defined by the housing.
 27. The apparatus of claim 21,wherein the adjustable member includes a threaded portion configured toreleasably couple the adjustable member to the housing.
 28. Theapparatus of claim 21, wherein the at least one biased member includes afirst biased member when the apparatus is in a first configuration, theat least one biased member including the first biased member and asecond biased member when the apparatus is in a second configuration,the occlusion member being configured to move from its first position toits second position when a pressure within the volume defined by thehousing rises above a first predetermined pressure when the apparatus isin the first configuration, the occlusion member being configured tomove from its first position to its second position when the pressurewithin the volume defined by the housing rises above a secondpredetermined pressure when the apparatus is in the secondconfiguration, the second predetermined pressure being greater than thefirst predetermined pressure.
 29. The apparatus of claim 21, wherein theocclusion member, the lumen defined by the at least one biased member,and the lumen defined by the adjustable member are substantiallycoaxial.